Automated inventory control system

ABSTRACT

An inventory management system for automatically generating a restocking order or prompting generation of a restocking order includes a storage space, a divider pivotable on the storage space between an upright position in which the divider separates the storage space into a front storage section and a rear storage section and a recumbent position that facilitates access to the rear storage section; and a motion detector module attached to the divider, the motion detector module including an accelerometer and a radio frequency transmitter in communication with the accelerometer and configured to emit radio frequency signals when the divider is rotated from the upright position to the recumbent position.

FIELD OF THE DISCLOSURE

This disclosure relates to inventory management and more specifically tosystems, apparatus and methods for automatically generating or promptingthe generation of a restocking order when a user selected quantity ofsupplies have been removed from shelving or bins where such supplies arestored.

BACKGROUND OF THE DISCLOSURE

Items that are routinely consumed in the process of conducting businessor providing services, such as in a hospital, clinic or industrialsupply room are typically stored in bins or storage modules positionedon shelves, or sometimes directly on shelves. As the stock or quantityof any particular item is depleted, it is important that the stock ofthat particular item is replenished. This can be of critical importancein the case of medical supplies. It is desirable and customary that areliable protocol is established for generating or prompting thegeneration of a restocking order well before there is risk that supplieswill be completely depleted and unavailable when needed. Preferably, therestocking protocol includes apparatus that compel medical techniciansor business personnel to generate or prompt generation of a restockingorder when the remaining stock of any particular stored item is depletedto a predetermined quantity.

U.S. Pat. No. 9,326,604, assigned to LogiQuip, LLC, Galesburg, Mich.,describes an inventory system for wire baskets or shelves, whichincludes a pivoting divider unit that subdivides individual bins intofront and rear sections and which is pivotable between an uprightposition that facilitates access to items stored in the front sectionand a forwardly-lowered position that facilitates access to items storedin the rear section when the items in the front section are completelydepleted. The divider can include a display panel that is visible whenthe divider is in the forwardly-lowered position and includes anindication or cue that restocking should soon occur. The indication can,for example, be a bar code that can be scanned with a reading device todetect the type of article and generate a replenishment order.

An object of this disclosure is to improve on the reliability ofexisting systems and reduce dependence on human participation in theprocess of generating a replenishment order. Another object is toincorporate apparatuses and methods that enable generation and trackingof data relating to the condition of stored items.

SUMMARY OF THE DISCLOSURE

Improved inventory control is achieved using a motion detection modulethat is attachable to a divider that separates a storage space into afront section having a primary supply of a particular item and a rearsection having a reserve supply of the item. The divider is rotatablebetween an upright position that allows access to items in the frontsection and limits or prevents access to items in the rear section, anda recumbent position that allows access to items in the rear sectionwhen all items in the front section have been removed. Rotation of thedivider to the recumbent position is detected by an accelerometer on thedivider, which in turn causes a transmitter on the module to emit asignal indicating that restocking is needed.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a motion detection module mounted on abin divider.

FIG. 2 is a top view of the motion detection module.

FIG. 3 is a front view of the motion detection module.

FIG. 4 is a side view of the motion detection module.

FIG. 5 is an exploded perspective illustration of the components andassembly of the motion detection module.

FIG. 6 is a perspective view of an inventory management system having adivider in the upright position.

FIG. 7 is a perspective view of the inventory management system of FIG.6 with the divider in the recumbent position.

FIG. 8 is a top view of the circuit substrate and electrical componentsmounted on the circuit substrate.

FIG. 9 is a side view showing a hinge clip that allows rotation of adivider on a floor of a wire shelf.

FIG. 10 is a perspective view of an alternative embodiment in which adivider is rotatably mounted on a base positioned in a bin.

FIG. 11 is a schematic illustration of a system comprising a pluralityof bins, each having a divider and an associated motion detectionmodule.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

A motion detection module 10 used in an inventory management system isshown (FIG. 1) releasably attached to a divider 12 that can be pivotablyconnected to a floor or bottom wall 14 of a storage space (as shown inFIGS. 6 and 7) of a storage unit 16. The storage space can, for example,be defined by a wire shelf, a wire basket, a bin, a shelf having anuninterrupted surface, or other structure capable of storing items.

The illustrated module 10 includes a circuit substrate 18 on which aremounted electrical components, including an accelerometer 20, a radiofrequency transmitter 22, and a light emitting diode (LED) 24 (FIGS. 5and 8). Other electrical components that can be incorporated on thecircuit substrate include sensors (e.g., temperature or humiditysensors), and a battery voltage detector. Data from such sensors anddetectors can be communicated to remote computers or system users toprovide notification, for example, that stored items are at risk ofbeing damaged by the existing conditions, or that batteries need to bechanged. Circuit substrate 18 is a support structure with integratedelectrical leads or conductors, such as a printed circuit board.Suitable accelerometers include miniature electromechanical devices thatmeasure acceleration. For example, various suitablemicroelectromechanical systems (MEMS) based devices relying onpiezoelectric, piezoresistive or capacitive effects are commerciallyavailable (e.g., LIS3DH nano-accelerometer available fromSTMicroelectronics, Geneva, Switzerland). Printed electrical leads (notshown) on the circuit substrate 18 provide electrical communication fromaccelerometer 20 to transmitter 22 to facilitate generation of a radiofrequency signal when a predetermined amount of movement has beendetected. Accelerometer 20 can include programmable thresholds that canbe set to help ensure that a false signal is not generated such as whenthe divider 12 or module 10 is bumped or jolted, and not actuallyrotated forwardly to facilitate access to items stored rearwardly ofdivider 12.

Motion detection module 10 includes a power source 24 (e.g., disposableor rechargeable batteries, such as standard AAA batteries or coin typebatteries), electrical contacts 26, 27, 28 for conducting electricalcurrent from power source 24 through the circuitry and electricalcomponents (e.g., 20, 22) on circuit substrate 18, and a housingcomprised of components that may include a main housing body 30, a frontcover 32 and a battery door 34 (FIGS. 2-5). Substrate 18 and componentsmounted thereon (e.g., accelerometer 20 and radio frequency transmitter22), as well as power source 24 are contained within the housing. Frontcover 32 and main housing body 30 can be joined together in any suitablefashion, such as with mechanical fasteners, adhesive fasteners, orinterlocking features. Battery door 34 is releasably attached to mainhousing body 30 by tabs 36 and detent 38.

A clip 40 is attached to the housing (e.g., to main housing body 30) tofacilitate releasable attachment of module 10 to a divider 12. In theillustrated embodiment, clip 40 is fastened to body 30 with screws 42.However, alternative arrangements are possible, such as attaching clip40 to cover 34. Attachment of clip 40 to the module housing can beachieved using alternative mechanical fasteners (e.g., staples),adhesive fasteners (e.g, glue), or interlocking mechanical features.Illustrated clip 40 includes a base portion 44 that is configured toengage a front surface 48 of divider 12 and a cantilevered portion 46that is configured to engage an opposite rear surface of divider 12.Clip 40 can be made of an injection molded resilient thermoplasticmaterial with a gap between the base portion 44 and cantilevered portion46 being smaller than the thickness of divider 12, such that clip 40 iscapable of resiliently retaining module 10 on divider 12.

In the illustrated embodiment, module 10 is configured for releasableattachment to a divider having an inverted (upside down) L-shapedprofile including a main vertical section 50 and a horizontal ledgesection 52. Horizontal ledge section 52 includes a downwardly andrearwardly bent return subsection 54. A tab 56 projects from uppersurface 58 of main housing body 30 to resiliently engage a gap betweenhorizontal ledge 52 and return 54 to stabilize retention of module 10 ondivider 12.

In accordance with certain preferred embodiments, an electromechanicalswitch 60 is provided on circuit substrate 18. Switch 60 is electricallyconnected to the circuitry and electrical components on substrate 18 toswitch on (or off) module 10 (i.e., actuate or power the module). Switch60 also mechanically interacts with a button actuator 62 that projectsfrom an opening through front cover 32 of the module housing.

In accordance with certain preferred embodiments of module 10, an LED 24is in electrical communication with the circuitry and components mountedon substrate 18 to provide a visual indication of the condition of themodule. For example, the LED can emit light continuously to indicate amodule “on” condition, and/or it can flash or pulse to indicate a lowbattery condition and/or a malfunction. A light pipe 64 can be providedto propagate light from LED 24 to an aperture 66 through front cover 32.

Module 10 can alternatively be configured differently for eitherpermanent or releasable attachment to a divider having a structuredifferent from that of divider 12. For example, module 10 could beconfigured without tab 56 and clip 40 could be rotated 90 degrees suchthat the bridge joining base 44 to cantilevered section 46 facesupwardly to engage a top edge of a divider having a flat profile withoutledge 52 or return 54. Releasable attachment as used in this disclosureand the appending claims refers to an attachment that can be reversedwithout damage to any components, and can preferably be achieved withouttools.

The inventory management systems 16 of this disclosure can comprise astorage bin or shelf 14 and a divider 12 that is rotatable from anupright position (as shown in FIG. 6), in which the main planar portion50 of divider 12 acts as a wall separating a front section of the bin orshelf space from a rear section of the bin or shelf space, to arecumbent position (as shown in FIG. 7), in which the divider ispositioned forwardly and downwardly from the upright position tofacilitate access to items stored in the rear section of the bin orshelf space.

In the embodiment illustrated in FIGS. 6 and 7, divider 12 is rotatablyjoined to wires comprising the floor or bottom wall 14 of a bin or shelfof storage unit 16 by two hinges 70, which are substantially identicalto the hinge units or hinge clips described in U.S. Pat. No. 9,326,604,which is incorporated in its entirety herein. Desirably, the hinge 70includes a feature (e.g., locking member 72, FIG. 9) that providesresistance to rotation until a deliberate effort is made to rotatedivider 12 to facilitate access to items in the rear section of the binor shelf area.

As used herein the term “bin” is distinguished from shelf space based onthe bin having side walls (e.g., wire walls 74), whereas a shelf spacecan be defined without such side walls. Shelf spaces without sidewallscan be suitable for storing certain items, such as items that store flatand/or items that can be stored in a nested arrangement.

In general, the divider is positioned so that the rear section of thebin or shelf space can accommodate a quantity of items that will not beexhausted during the time needed for restocking.

FIG. 10 shows an alternate embodiment in which a divider 90 is rotatablymounted on a base 92 and placed in a bin 94 having a continuous,uninterrupted floor, side walls, back wall and front wall. Bin 94 can beplaced on shelves of a storage unit.

FIG. 11 is a schematic illustration of an automated inventory controlsystem 100 comprising a plurality of bins or shelf spaces 101. Each binhas a module 10, as described above, that is mounted on a divider 12. Asingle consolidator 102 can be provided to receive transmissions frommodules 10 when the associated divider is rotated to the recumbentposition. The individual transmitters in the modules 10 are programmedor configured to transmit a signal indicative of the item associatedwith that particular module. The programmed transmissions may alsoinclude additional information such as the specific location of the bin(e.g., storage unit number, shelf number, bin number, etc.).Consolidator 102 includes a radio frequency receiver for receivingtransmissions from the individual modules 10, and a processor forgenerating restocking orders or for prompting generation of arestocking. Such orders or prompt can be communicated to a remotecomputer or computers via a network (e.g., a local area network, or theworld wide network or Internet). Such order or prompt can includeinformation regarding the item that needs to be restocked, therestocking quantity, and the location of the bin or shelf that needs tobe restocked.

Accordingly, it is to be understood that the above description isintended to be illustrative and not restrictive. Many embodiments andapplications other than the examples provided would be apparent uponreading the above description. The scope of the invention should bedetermined with reference to the appended claims along with the fullscope of equivalents to which such claims are entitled. It isanticipated and intended that future developments will occur, and thatthe disclosed systems and methods will be incorporated into such futureembodiments. In summary, it should be understood that the invention iscapable of modification and variation.

What is claimed is:
 1. An inventory management system, comprising: astorage space having a floor; a divider pivotable on the floor of thestorage space between an upright position in which the divider separatesthe storage space into a front storage section and a rear storagesection and a recumbent position in which the divider is positionedforwardly and downwardly from the upright position to facilitate accessto the rear storage section; and a motion detector module attached tothe divider, the motion detector module including an accelerometer and aradio frequency transmitter in communication with the accelerometer andconfigured to emit radio frequency signals when the divider is rotatedfrom the upright position to the recumbent position, wherein the housingincludes a tab projecting from an upper surface of the housing forresiliently engaging a return leg on an upper horizontal ledge portionprojecting from a vertical portion of a divider, and a clip having abase portion that is configured for engaging a first face of a dividerand a cantilevered portion for engaging a second face of the divideropposite the first face, whereby the motion detector is releasablyattachable to the divider.
 2. The inventory management system of claim1, further comprising a consolidator including a radio frequencyreceiver for detecting a signal from the transmitter of the motiondetector module and a processor for communicating restocking informationto fill or generate a restocking order.
 3. The inventory managementsystem of claim 1, wherein the motion detector module further comprisesat least one battery for powering the sensor and radio frequencytransmitter.
 4. The inventory management system of claim 3, wherein themotion detector module further comprises a circuit substrate on whichelectrical components are mounted, said electrical components includingthe sensor and the radio frequency transmitter, and an actuator buttonfor turning on power to the electrical components mounted on the circuitsubstrate.
 5. The inventory management system of claim 4, furthercomprising a housing containing the circuit substrate, an LED mounted onthe circuit substrate, and a light pipe extending from the LED andthrough an aperture of the housing for propagating light from the LED toa front face of the module housing to indicate a condition of themodule.
 6. A motion detector module, comprising: a circuit substrate; apower source for powering electrical components mounted on the circuitsubstrate; an accelerometer mounted on the circuit substrate; a radiofrequency transmitter mounted on the circuit substrate, the radiofrequency transmitter being in electrical communication with theaccelerometer to generate a radio frequency signal when a predeterminedamount of movement has been exceeded; a housing containing the circuitsubstrate, power source, accelerometer and radio frequency transmitter;and a clip having a base configured to engage a front surface of adivider that is pivotable on a floor of a storage space, and acantilevered portion configured to engage an opposite rear surface ofthe divider, the clip attached to the housing; and a tab projecting froman upper surface of the housing for resiliently engaging a return leg onan upper horizontal ledge portion of the divider, the tab and the clipconfigured to releasably attach the motion detection module to thedivider.
 7. The motion detector module of claim 6, wherein the powersource comprises at least one battery.
 8. The motion detector module ofclaim 6, further comprising an actuator button for turning on power tothe electrical components mounted on the circuit substrate.
 9. Themotion detector module of claim 6, further comprising an LED mounted onthe circuit substrate and a light pipe extending from the LED andthrough an aperture of the housing for propagating light from the LED toa front face of the module housing to indicate a condition of themodule.
 10. A method of generating a restocking order for a storagespace, comprising: providing a storage space having a floor and adivider pivotable on the floor between an upright position that dividesthe storage space into a front storage section and a rear storagesection and a recumbent position in which the divider is positionedforwardly and downwardly from the upright position to facilitate accessto the rear storage section; and providing a motion detection module onthe pivotable divider, the motion detection module including anaccelerometer and a radio frequency transmitter in electricalcommunication with the accelerometer to transmit a radio frequencysignal when the divider is pivoted from the upright position to therecumbent position, wherein the housing includes a tab projecting froman upper surface of the housing for resiliently engaging a return leg onan upper horizontal ledge portion projecting from a vertical portion ofa divider, and a clip having a base portion that is configured forengaging a first face of a divider and a cantilevered portion forengaging a second face of the divider opposite the first face, wherebythe motion detector is releasably attachable to the divider.